Classification of numerical, experimental, and analytical approaches for gearbox oil flow and no-load gear power loss

Hildebrand, Lucas; Liu, Hua; Paschold, Constantin; Lohner, Thomas; Stahl, Karsten

doi:10.1016/j.jestch.2024.101661

Engineering Science and Technology, an International Journal

2024

DOI: 10.1016/j.jestch.2024.101661

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Classification of numerical, experimental, and analytical approaches for gearbox oil flow and no-load gear power loss

Lucas Hildebrand,

Hua Liu,

Constantin Paschold

et al.

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2024

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Cited by 2 publications

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Numerical Calculation of the Oil Flow in a Truck Rear Axle Transmission and the Influence of Gear-Induced Air Flow

Hildebrand,

Beierer,

Lohner

et al. 2024

Journal of Tribology

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For the reliable operation of a gearbox, consistently sufficient lubrication of tooth contacts and bearings is necessary. Thus, gearbox oil flow plays an important role. Additionally, air flow may affect the oil flow in the gearbox. The state of the art indicates that Computational Fluid Dynamics (CFD) enables targeted support of the gearbox development process at an early stage. Computational time plays a prominent role in practical applications due to associated costs. The particle-based Smoothed Particle Hydrodynamics (SPH) shows great potential for time-efficient calculations, especially with a simplified single-phase modeling approach. This study examines the influence of gear-induced air flow on gearbox oil flow, focusing on a test gearbox to identify a suitable modeling approach for a truck rear axle transmission. The results indicate that for the investigated operating conditions, the gear-induced air flow only impacts gearbox oil flow at higher circumferential speeds. For lower circumferential speeds, a single-phase SPH yields good results with significantly reduced computation times compared to the two-phase SPH. Applying the single-phase SPH to the truck rear axle transmission and comparing numerical results with experimental findings demonstrates a reliable representation of the oil flow characteristics.

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Numerical Calculation of the Oil Flow in a Truck Rear Axle Transmission and the Influence of Gear-Induced Air Flow

Hildebrand,

Beierer,

Lohner

et al. 2024

Journal of Tribology

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Development of a gearbox test rig to evaluate the impact of oil formulations on churning and friction losses

Tomanik,

Getschko,

Papoulias

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part J:

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From large industrial to small high-speed transmission for electric vehicles, there is a growing interest in reducing the power losses on gearboxes. Hydrodynamic losses are especially relevant on high-speed gearboxes. On electric cars, the gearbox lubricant also works as a cooling fluid for the motor, which brings new challenges as performance under an electrified environment, thermal and electrical conductivity, corrosion protection etc. Most current test rigs use the torque difference between gearbox output and input to calculate the power losses. This work, uses the instantaneous deceleration on a small gearbox to obtain the no-load depending on power losses. Due to its simplicity, the proposed method has the potential to be applied to actual transmissions with very simple sensors and without the need for significant intervention on the actual equipment. The experimental results showed increased churning power losses with the immersion depth and oil viscosity. With the tested transmission oils, the churning losses showed to depend on rotational speed by a power of three, as predicted by the ISO model. The influence of oil viscosity was less evident. Reducing viscosity 2.5 times showed only around 25% reduction in the calculated churning losses. In opposition to the tested transmission oils, a low-viscosity oil with Friction Modifier additives reduced the power losses with the consecutive larger volumes of sump oil, such unexpected result can be explained by the beneficial effect of the oil FM additives.

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Classification of numerical, experimental, and analytical approaches for gearbox oil flow and no-load gear power loss

Cited by 2 publications

References 17 publications

Numerical Calculation of the Oil Flow in a Truck Rear Axle Transmission and the Influence of Gear-Induced Air Flow

Numerical Calculation of the Oil Flow in a Truck Rear Axle Transmission and the Influence of Gear-Induced Air Flow

Development of a gearbox test rig to evaluate the impact of oil formulations on churning and friction losses

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